Prefabricated roof construction with foamed plastic joining means



Jan. 31, 1967 LUTZE 3,300,931

PREFABRICATED ROOF CONSTRUCTION WITH FOAMED PLASTIC JOINING MEANS FiledSept. 15, 1964 4 Sheets-Sheet 1 III! i Jan. 31, 1967 LUTZE 3,300,931

PREFABRICATED ROOF CONSTRUCTION WITH FOAMED PLASTIC JOINING MEANS 4Sheets-Sheet 2 Filed Sept. 15, 1964 In ven for: G 12w 4d 12'- 9 N mEJan. 31, 1967 e. LUTZE 3,300,931

PREFABRICATED ROOF CONSTRUCTION WITH FOAMED PLASTIC JOINING MEANS FiledSept. 15, 1964 4 Sheets-Sheet 3 Fig. 4

In ventor:

GLENN LLZILLEV Jan. 31, 1967 a. LUTZE 3,300,93l

PREFABRICATED ROOF CONSTRUCTION WITH FOAMED PLASTIC JOINING MEANS FiledSept. 15, 1964 4 Sheets-Sheet 4 United States Patent PREFABRICATED ROOFCONSTRUCTION WITH FOAMED PLASTIC JOINING MEANS Giinter Liitze, UntereSteigstrasse 32, Reutlingen- I Ohmenhausen, Germany Filed Sept. 15,1964, Ser. No. 396,583

' Claims priority, application Germany, Sept. 17, 1963,

L 45,873 Claims. (Cl. 52-309) The present invention relates toprefabricated buildings in general, and more particularly to an improvedprefabricated roof which may be used in prefabricated houses and othertypes of building constructions.

It is an important object of the present invention to provide a verysimple, comparatively inexpensive, lightweight and compact prefabricatedroof whose component parts may be assembled in the manufacturing plantor at the locale of actual use.

It is another object of the invention to provide a prefabricated roofwhich is a highly satisfactory insulator against heat or cold, which maybe used in very hot or very cold climates without damage to its parts,which is constructed and assembled in such a way that its ceiling panelor panels are not likely to accumulate condensate water, wherein theceiling panel is not likely to buckle in response to substantialdilferences between outside temperature and room temperature, which mayserve as a carrier for an overhead heating system, and wherein at leastsome parts may consist of synthetic plastic or similar comparativelyinexpensive materials.

A further object of the invention is to provide a prefabricated roofwhich is capable of withstanding very high torsional, compressive and/or bending stresses, which may be manufactured in many different sizesand/ or shapes, which may be put to use in many types of prefabricatedbuildings, which may accommodate and is then capable of supportingflexible or rigid conduits, conductors, tubes, sheaths and similarelongated elements to convey electric current, gases or liquids in aprefabricated home or another type of dwelling, which may be providedwith composite or one-piece ceiling panels or roof skins, and wherein aceiling panel is automatically held at a requisite distance from theroof skin while being at the same time held against curling, buckling,cracking, and other types of damage and/or deformation.

A concomitant object of the invention is to provide a novel skeletonframe which may be utilized in a prefabricated roof of the aboveoutlined characteristics.

Still another object of the invention is to provide a novel method ofassembling a prefabricated roof of the above outlined type and ofconstructing the skeleton frame of the roof in such a way that it mayproperly support highly resistant metallic ceiling panels as well asmuch more sensitive ceiling panels of plaster or the like.

A further object of the invention is to provide the component parts ofthe skeleton frame with improved connectors which may contribute toretention and proper positioning of one or more ceiling panels and/orskins in a prefabricated roof of the above outlined characteristics.

Another object of the invention is to provide a prefabricated roof whichembodies a skeleton frame of the just outlined type and wherein theposition of connectors with Patented Jan. 31, 1967 ice reference to eachother and with reference to the elements of the skeleton frame may beadjusted prior to, during and following the assembly of the frame.

Briefly stated, one feature of my invention resides in the provision ofa method of producing a prefabricated roof which comprises the steps ofassembling a pair of longitudinal and a pair of transverse U-bars orsimilar metallic frame members with a series of spaced metallic ceilingjoists in the form of I-bars or otherwise profiled stock to form a rigidrectangular skeleton frame wherein the joists are disposed intermediateand in substantial parallelism with one pair of frame members, placing aone-piece or a composite ceiling panel of plaster, sheet aluminum or thelike onto a rigid horizontal support, providing at least some of thejoists (and preferably also the one pair of frame members) withdownwardly extending adjustable spacer elements of identical height,placing the spacer elements onto the ceiling panel so that the framemembers are located in a plane which is parallel with the plane of theceiling panel, filling in at least the larger ones of any such openingswhich might be present between the ceiling panel and the frame membersto form a shallow tray-shaped mold wherein the ceiling panel constitutesthe bottom portion, and introducing into the mold a hardenable liquidplastic bonding material which fills the mold up to a level high enoughto insure that the spacer elements are at least partially surrounded bythe plastic layer which is obtained upon hardening of bonding materialwhereby the layer adheres to the ceiling panel to connect the panel withthe remainder of the thus obtained prefabricated roof.

In accordance with an important feature of my invention, the upperflanges and/or the lower flanges of the joists (and referably also ofthe frame members which are parallel to the joists) are provided withelongated T-grooves which receive T-shaped beads of the spacer elementsso that each spacer element is held against separation from therespective joist or frame member but is freely slidable in thelongitudinal direction of the respective groove. This enables theersonnel to distribute the spacer elements in such a way that theyprotect the roof from buckling and take up the weight of the plasticlayer. The layer is preferably a hard body of foamed light-weightplastic material which is a good insulator of heat and may but need notbe at least slightly elastic.

The novel features which are considered as characteristic of theinvention are set forth in particular in the appended claims. Theimproved prefabricated roof itself, however, both as to its constructionand the mode of assembling and mounting the same, together withadditional features and advantages thereof, will be best understood uponperusal of the following detailed description of certain specificembodiments with reference to the accompanying drawings, in which:

FIG. 1 is a perspective view of a skeleton frame which is constructedand assembled in accordance with a first embodiment of my invention andwherein the lower flanges of the joists and transverse frame memberscarry rows of aligned L-shaped spacer elements or connectors;

FIG. 2 is an enlarged fragmentary perspective view of the skeleton frameand further illustrates a portion of a ceiling panel which abuts againstthe undersides of the connectors as well as a flexible conductor whichis led through the vertical flanges of certain connectors;

FIG. 3 is a greatly enlarged fragmentary bottom plan view of theskeleton frame shown in FIG. 1;

FIG. 4 is a greatly enlarged fragmentary vertical section through one ofthe transverse frame members and through a portion of the ceiling panelsubstantially as seen in the direction of arrows from the line 44 ofFIG. 3, further showing two wooden beams which are used while theinterior of the skeleton frame is being filled with a liquid plasticwhich is to form a foamed layer;

FIG. 5 is a vertical section substantially as seen in the direction ofarrows from the line 5-5 of FIG. 4;

FIG. 6 is a vertical section through a portion of a fully assembled roofwhich is shown in position on top of a prefabricated side wall and isconnected to a gutter; and

FIG. 7 is a fragmentary perspective view of a modified roof which isshown in partly assembled condition.

Referring to the drawings, and first to FIG. 1, there is shown arectangular skeleton frame 10 which is composed of two longitudinalframe members 11, 12 and two transverse frame members 13, 14. Theseframe members are metallic U-bars whose webs are located in verticalplanes. The width of webs on the longitudinal frame members 11, 12exceeds the width of webs on the transverse frame members 13, 14 so thatthe ends of the members 13, 14 may be fitted into the spaces between theupper and lower flanges of the members 11, 12. The lower flanges of thelongitudinal frame members 11, 12 support a series of equidistantceiling joists which are parallel to and are located between thetransverse frame members 13, 14. Of those lower flanges, only theflanges 11a are shown in FIGS. 2, 4 and 5. Each ceiling joist 15 is ametallic I-bar. For example, the frame members 11-14 and the joists 15may consist of aluminum and the ends of the members 13, 14 and joists 15are welded to the members 11, 12 to thus form a rigid skeleton frame. Itwill be noted that the flanges of the frame members 11, 13 face theframe members 12, 14 and vice versa, i.e., the flanges of all framemembers extend into the space surrounded by their webs.

The flanges 13a, 14a and 15a on the transverse frame members 13, 14 andceiling joists 15 are provided with longitudinally extending T-grooves16. The grooves 16 in the upper flanges extend downwardly so that theirenlarged portions are spaced from the upper sides of such upper flanges.The grooves 16 in the lower flanges extend upwardly and their enlargedportions are located above the undersides of such lower flanges. Thelower flanges 13a, 14a, 15a are located in a common plane just above thecommon plane of the lower flanges of the frame members 11, 12. The lowergrooves 16 accommodate T-shaped beads 17a at the upper ends ofsubstantially L-shaped (profiled) connectors 17, best shown in FIG. 4,which are located at a level below the frame 10 and preferably consistsof corrosion-resistant synthetic plastic material which is a poorconductor of heat. The connectors 17 serve as retainers and/ or spacerelements for a ceiling panel shown in FIG. 2. The lower flanges of theconnectors 17 on a common lower flange 15a face away from each other,see FIG. 2, and it will be noted that the grooves 16 on the lowerflanges 15a are provided along the respective edges of such lowerflanges whereby the edges may be reinforced to insure that they maysupport considerable weight. The enlarged portions of the beads 17a fillor nearly fill the corresponding lengths of enlarged portions of thelower grooves 16 to insure that they are free to slide but will be heldwithout undue wobbling. The connectors 17 may be inserted from one endof the respective ceiling joist 15 before the latter is welded to thelongitudinal frame members 11, 12. The lower flange 13a, 14a of eachtransverse frame member is provided with a single T- groove 16, and suchgrooves also receive the beads 17a of a requisite number of properlyspaced connectors 17. This is best shown in FIG. 1 wherein the lowerflange 14a of the frame member 14 carries six equidistant connectors 17.The operators resort to suitable rulers or the like to insure that thealigned connectors are properly spaced from each other, i.e., that theconnectors may properly support a one-piece ceiling panel 30 or acomposite ceiling panel which consists of several coplanar sections orsheets. The connectors 17 on one of the joists 15 may but need not bealigned with the connectors of one or more additional joists and/or withthe connectors of one or both transverse frame members. It is up to theoperators to decide upon the optimum distribution of connectors on theskeleton frame 10 of FIG. 1.

In accordance with an important feature of my invention, the number ofconnectors on any given joist 15 or transverse frame member 13, 14 maybe changed at any time, not only before the parts 13, 14, 15 are weldedto the frame members 11, 12. As best shown in FIGS. 2 and 3, the grooves16 comprise enlarged zones or cutouts 16b which are wide and long enoughto allow for insertion or removal of a bead 17a. The width of eachcutout 16b at least equals, the maximum width of the respective grooves16, i.e., it exceeds at least slightly the width of a bead 17a, and itslength exceeds the length of a bead 17a. All that an operator has to doin order to remove a connector 17 is to slide it to the nearest cutout16b and to simply withdraw the bead 17a therethrough. It is clear thateach groove 16 may be provided with two or more cutouts, depending onthe length of the joists 15 and transverse frame members 13, 14, and itis equally clear that such cutouts are also provided in the lowergrooves 16, see FIG. 3. As a rule, the cutouts 16b will be provided nearthe ends of the respective flange 13a, 14a, 15a and it normally sufficesto provide each groove 16 with a single cutout. If the operator desiresto insert an additional connector 17 into one of the lower grooves 16,he merely pushes the bead 17a upwardly and into the cutout 16b of therespective groove; the head is thereupon slipped into that portion ofthe groove which is adjacent to the cutout and the connector is safelyattached to the respective joist or transverse frame member.

FIG. 2 shows that the vertical flanges of some or all connectors 17 maybe provided with one or more circular apertures 17c which serve toaccommodate portions of electric cables 18 (shown by phantom lines),tubular sheaths for electric cables, conduits for a fluid medium orother solid rod-like or tubular bodies which might be necessary in theelectric, hydraulic or pneumatic circuitry of a building constrcution.If the cables 18 are sufliciently flexible, they may be laid in anydesired pattern, i.e., they may form bodies of zig-zag, undulate or anyother desired shape. It is clear that the apertures 170 may be replacedby apertures in the form of semicircular slots which are then providedin the vertical end faces of the connectors 17 so that the cables 18need not be threaded through the apertures 17c but are simply pushedlaterally to enter the corresponding slots.

The frame members 11-14 are provided with downwardly extendingextensions or skirts 11c, 12c, 13c, which are coplanar with therespective webs and may be received in complementary recesses providedin the top faces of side Walls in a prefabricated building wherein theimproved roof is put to use. The lower end faces of the skirts 11c14care located in a common horizontal plane which is closely adjacent to orcoincides with the common plane of the undersides of the bottom flangeson the connectors 17.

As shown in FIG. 6, the upper T-grooves may receive special types ofconnectors 19 (hereinafter called coupling elements to diflerentiatefrom the connectors 17) which serve to retain an upper panel or roofskin 20. Each coupling element 19 comprises a downwardly extendingT-shaped bead 19a corresponding to a bead 17a and accommodated in therespective upper T-groove to insure that the coupling element may beshifted in the longitudinal direction of the respective joist 15 ortransverse frame member 13 or 14. In FIG. 6, the coupling element 19 ismounted in the upper T-groove of the transverse frame member 14, andthis element further comprises two mirror symmetrical elastic tongues19b which are received in a depression 20a of the roof skin 20. The sidewalls of the depression 20a are located at such a distance from eachother that the tongues 19!) are deformed and their inverted hook-shapedend portion 19c engage the inner sides of such side walls and therebyanchor the coupling element 19 in the roof skin. The marginal portions20b of the roof skin 20 extend "vertically downwardly and overlieportions of specifically configurated brackets 21 (only one shown) whichin turn overlie the upper flanges of the transverse frame members 13,14. The bracket 21 shown in FIG. 6 serves as a gutter and collects waterwhich overflows the edges of the roof skin 20. The outer portion of thebracket 21 carries a detachable shield 22 which serves as an adornmentfor the roof construction and forms no part of the present invention.

FIG. 6 also shows the upper portion of a side wall 24 which supports thetransverse frame member 14. The uppermost portion of the side wall 24consists of a hollow horizontal box-shaped carrier 25 (also calledplate) whose top wall is provided with a recess 25a to receive the skirt140. The wall 24 is a prefabricated body comprising an outer skin 23which overlies and adheres to the outer side of the carrier 25 and aninsulating layer 26 of foamed plastic material or the like. The innerside of this insulating layer is coated with a layer 27 of plaster. ItWill be noted that the width of the recess 25a exceeds the thickness ofthe skirt 14c so that this recess may receive a second skirt, forexample, when the side wall 24 constitutes a partition in aprefabricated building. Thus, a second prefabricated roof may be placedend-to-end with the roof of FIG. 6 to have one of its skirts supportedby the wall 24. Of course, the bracket 21 is then removed to provideroom for a transverse frame member which is placed next to the framemember 14 of FIG. 6. When the recess 25a receives a single skirt, it isshielded from snow, rain or dust by the bracket 21 which is locatedabove the carrier 25 and is sealingly secured to the transverse framemember 14 by the downwardly extending marginal portion 20b of the roofskin 20.

The dimensions of the ceiling panel 20 are selected in such a way thatthe edges of this panel do not extend all the way to the skirts 11c,13c, 12c, 140, see FIG. 6. Thus, there is room for theh upper portion ofthe side Wall 24 whereby the right-hand edge of the panel 20 abutsagainst the inner side of the plaster layer 27. Depending on itscomposition, the panel 30 may be glued, welded or otherwise detachablyor permanently secured to the connectors 17, i.e., to the horizontalbottom flanges of the connectors.

The skeleton frame 10 of FIG. 1 may be utilized in a number of ways. Asshown in FIGS. 4 and 5, this frame may be placed onto a prefabricatedceiling panel 30 which is assumed to consist of plaster and rests on theupper side of a horizontal table. The dimensions of the panel 30 aresmaller than the dimensions of the frame 10. It is clear that the panel30 may consist of several sections or smaller panels and, if the panel30 is a composite structure, the connectors 17 are preferably shiftedand distributed in such 'a way that they overlie the edges of adjoiningsections. As a rule, the edges of adjoining panel sections will beseparated by narrow gaps which, if necessary, can be filled in frombelow when the roof is fully assembled. In order to proper- 1y locatethe panel 30 with reference to the frame 10, the workmen may resort towooden filler beams or battens 31, 32 whose upper sides are providedwith recesses 31a, 32a, corresponding to the recess 25a of the carrier25 and serving to receive the respective skirts 11c, 12c, 13c, 140. Thebeams 31 are parallel With the transverse frame members 13, 14 and thebeams 32 are parallel with the longitudinal frame members 11, 12. Theparts 1114, 15 (not shown in FIGS. 4 and 5) 30, 31 and 32 then form ahollow tray-shaped mold which is thereupon filled, or nearly rfilled,with a liquid plastic bonding material containing a suitable blowingagent. After setting, the plastic material forms a foamed layer 33 whichis preferaby at least slightly elastic and constitutes an excellentinsulator against heat or cold by simultaneously connecting the panel 30with the remainder of the thus obtained prefabricated roof. Any of thevarious methods of producing foamed plastic bodies may be used. Thislayer 33 is of such thickness that it preferably surrounds all of theconnectors 17 and also extends above the lower flanges 13a-15a to serveas a rigid and highly reliable support for the ceiling panel 30. Inaddition, the material of the layer 33 surrounds the connectors 17 whichare thereby anchored in selected positions of adjustment and keep theceiling panel 30 at a requisite distance from the lower flanges 15a ofthe ceiling joists 15. In other words, when the layer 33 is formed in 'amanner as illustrated in FIGS. 4 and 5, the connnectors 17 mainly serveas spacer elements or distancing elements to insure that the panel 30 iskept at a requisite distance from the skeleton frame 10. In addition,the connectors 17 perform the important function of preventingnon-uniform expension or contraction or a prefabricated roof as Well asto interrupt the socalled cold bridge. The connectors may be severedfrom a length of extruded plastic material which may be of L-profile asshown in the drawings. T-shaped connectors may be used if desired.

Once the roof is fully assembled, i.e., once the layer 33 h-ardens, thefillers 31, 32 are removed and the resulting structure is ready to beplaced onto four side walls 24 in a manner as shown in FIG. 6. However,if the roof is to simply rest on the top faces of four side walls, thefillers 31, 32 are dispensed with and the .panel 30 then extends 'allthe way to the skirts 11c, 12c, 13c, 140. The fact that the edges of thepanel 30 are not in full sealing engagement with the skirts 11c14c (whenthe fillers 31, 32 are not used) is of no consequence because thematerial of the layer 33 normally sets very rapidly so that losses inliquid plastic are negligible.

It goes without saying that the method described in connection withFIGS. 4 and 5 may be modified in a number of ways without departing fromthe spirit of my invention. Thus, and if one or more frame members 1114should consist of two or more sections or if a frame member is to beprovided with one or more cutouts or other forms of openings throughwhich the liquid plastic would escape during pouring of the layer 33,the operators will resort to differently shaped and/or dimensionedfillers which will temporarily close the openings and are removed assoon as the material of the layer 33 hardens. This layer may but neednot extend all the way to the upper flanges of the frame members 11-14,but it should be thick enough to insure that the panel 30 is held withrequisite force and that this panel is not likely to curl. If the panel30 consists of several coplanar sections which are separated by narrowgaps, the material of the layer 33 automatically fills such gaps so thatthe gaps are sealed and the underside of the panel may be finished withlittle expenditure in time or material. In other words, the pouring ofliquid plastic is tantamount to caulking of a composite ceiling panel.

If the nature of the prefabricated building in such that theprefabricated roof should be provided with a cavity, recess or chamber,the operators will form a suitable insert of wood or the like, and thisinsert is then placed into the mold prior to pouring of liquid bondingmaterial. Once the material sets to form the layer 33, the insert isremoved and the roof is provided with a chamber or recess of desiredshape.

The panel may consist of plaster, sheet aluminum, plywood or any othersuitable material.

Referring to FIG. 7, there is shown a somewhat modified prefabricatedroof structure which again comprises a rectangular skeleton frameincluding a longitudinal frame member 31 which corresponds to the framemember 11 of FIG. 1. The ceiling joists are shown at 35 and their lowerflanges carry connectors 37 and tubular coupling elements 39 to supportand/or to locate a ceiling panel Each joist 35 is provided with a singleupper T-groove 36 and with a single lower T-groove (not shown), and itwill be noted that these grooves are coplanar with the vertical webs ofthe respective joists. Each groove is provided with one or more cutouts36b. The T-shaped beads 37a of the connectors 37 extend into the lowergroove of the left-hand joist 35 and the lower groove of the right-handjoist 35 receives the beads 39a of a series of aligned tubularconnectors 39. Each connector 39 comprises a lower portion 39b ofpolygonal cross section, e.g., of rectangular cross section, andcomprises a horizontal partition 39:: which divides the interior of therespective connector 39 into an upper channel-shaped aperture 39d and alower channel-shaped aperture 39c. The lower apertures 39s replace theapertures 17c and accommodate one or more cables 38 (shown by phantomlines) or analogous rigid or flexible conductors or conduits. Of course,the upper apertures 39d may also serve to receive one or more cables orconduits; alternatively, all conduits may be led through the apertures39d and all conductors may be led through the apertures 39c, or viceversa.

A very important advantage of connectors 17, 19, 37 and 39 is that theydo not form a continuous connecting body between the joists (and certainframe members) and the ceiling panel. Thus, the rate at which theceiling panel may exchange heat with the skeleton frame is much lessthan if each row of connectors were replaced by a continuous length ofmetallic or plastic material. The fact that the connectors preferablyconsist of a material which is a poor conductor of heat also contributesto improved heat insulating characteristics of the roof. The material ofthe layer 33 may be at least slightly elastic so that it yields inresponse to twisting stresses and will keep the ceiling panel fromcracking. The connectors may be made of slightly elastic syntheticplastic material. Since the ceiling panel is insulated from the skeletonframe, it is not likely to accumulate water of condensation when thetemperature at the underside of the ceiling plate is much higher thanthe temperature of the skeleton frame. Furthermore, and since thematerial of the layer 30 and/or the material of the connectors 17, 19,37, 39 is preferably at least slightly elastic, the ceiling panel isfree to expand or contract with respect to the skeleton frame or viceversa. This is of particular importance when the ceiling panel is madeof sheet aluminum and the building in which the prefabricated roof isput to use comprises an overhead heating system which heats the ceilingpanel while the skeleton frame is exposed to much colder atmosphericair.

Owing to the fact that the connectors are readily slidable in therespective T-grooves, the skeleton frame may be assembled by weldingwithout any danger that heat which develops in the course of a weldingoperation would damage or destroy the connectors. Thus, all theoperators must do it to shift the connectors v17 far away from the framemember 12 (see FIG. 1) when the front ends of the joists 15 and framemembers 13, 14 are welded to the frame member 12. Once the joints aresufficiently cool to avoid destruction of plastic connectors, the latterare shifted in close proximity to the member 12 and the joists 15 andframe members 13, 14 are then welded to the frame member 11. In otherwords, even if the cutouts 16b, 36b are omitted, so that the connectorsmust be secured to the respective U-bars and I-bars before the skeletonframe is assembled, the connectors are still protected from damage whilethe operatOrs proceed to join the ends of the members 13, 14 and joists15 to the frame members 11, 12. The provision of cutouts 16b, 36b is ofparticular advantage when the skeleton frame is assembled in a plant andis transported to the locale of actual use where the operators attach asmany connectors as are necessary for a prefabricated roof of desiredsize and/or shape. Connectors 17, 19, 37, 39 may be made of polyvinylchloride, Bakelite or the like. The liquid used to form layer 33 may byway or conduits. Of course, the upper apertures 39d may cyanates.

Without further analysis, the foregoing will so fully reveal the gist ofthe present invention that others can, by applying current knowledge,readily adapt it for various applications without omitting featureswhich fairly constitute essential characteristics of the generic andspecific aspects of this invention and, therefore, such adaptationsshould and are intended to be comprehended within the meaning and rangeof equivalence of the following claims.

What is claimed as new and desired to be secured by Letters Patent is:

1. In a prefabricated roof, in combination, a skeleton frame comprisingpairs of longitudinal and transverse frame members and a plurality ofspaced joists disposed between and substantially parallel to one pair ofsaid frame members, said one pair of frame members and said joistshaving undersides provided with longitudinally extending grooves havingenlarged portions spaced from the respective undersides; at least oneconnector for at least some of said grooves, said connectors beinglocated at a level below said undersides and having enlarged portionsextending into and slidable in the enlarged portions of thecorresponding grooves; a panel adjacent to said connectors; and a layerof adherent foamed plastic material surrounding said connectors andadhering to said panel to connect said panel to said skeleton frame.

2. In a prefabricated roof, in combination, a metallic skeleton framecomprising pairs of longitudinal and transverse U-bars and a pluralityof spaced I-bars disposed between and substantially parallel with onepair of said U-bars, said one pair of U-bars and said I-bars comprisingsubstantially horizontal lower flanges located in a common plane andhaving undersides provided with longitudinally extending T-grooves; atleast one profiled connector for at least some of said grooves, saidconnectors being located at a level below said undersides and havingT-shaped beads extending into and slidable in the respective T-grooves;a panel adjacent to said connectors; and a layer of adherent foamedplastic material surrounding said connectors and adhering to said panelto connect said panel to said skeleton frame.

3. In a prefabricated roof, in combination, a metallic skeleton framecomprising pairs of longitudinal and transverse U-bars and a pluralityof spaced I-bars disposed between and substantially parallel with onepair of said U- bars, said one pair of U-bars and said I-bars comprisingsubstantially horizontal lower flanges located in a common plane andhaving undersides provided with longitudinally extending T-grooves; atleast one profiled connector for at least some of said grooves, saidconnectors being located at a level below said undersides and havingT-shaped beads extending into and slidable in the respective T-grooves,each connector further having a substantially horizontal bottom flangecoplanar with the bottom flanges of the other connectors; a ceilingpanel adjacent to and located below said bottom flanges and a layer ofadherent foamed plastic material surrounding said connectors andadhering to said panel to connect said panel to said skeleton frame.

4. In a prefabricated roof, in combination, a metallic skeleton framecomprising pairs of longitudinal and transverse U-bars and a pluralityof spaced I-bars disposed between and substantially parallel with onepair of said U-bars, said bars comprising substantially horizontal upperand lower flanges and the lower flanges of said I-bars and said one pairof U-bars being located in a common plane and having undersides providedwith longitudinally extending T-grooves, the flanges of each of saidU-bars facing the other U-bar of the respective pair; at least oneprofiled connector for at least some of said grooves, said connectorsbeing located at a level below said undersides and having T-shaped beadsextending into and slidable in the respective T-grooves; a paneladjacent to said connectors; and a layer of adherent foamed plasticmaterial surrounding said connectors and adhering to said panel toconnect said panel to said skeleton frame.

5. In a prefabricated roof, in combination, a metallic skeleton framecomprising pairs of longitudinal and transverse frame members and aplurality of spaced joists disposed between and substantially parallelto one pair of said frame members, said one pair of frame members andsaid joists having undersides provided with longitudinally extendinggrooves having enlarged portions spaced from the respective undersides;at least one connector for at least some of said grooves, saidconnectors being located at a level below said undersides and havingenlarged portions extending into and slidable in the enlarged portionsof the corresponding grooves, each of said connectors consisting ofsynthetic plastic material which is a poor conductor of heat; a ceilingpanel adjacent to and located below said connectors; and a layer ofadherent foamed plastic material surrounding said connectors andadhering to said ceiling panel to connect said ceiling panel to saidframe.

6. In a prefabricated roof, in combination, a skeleton frame comprisingpairs of longitudinal and transverse frame members and a plurality ofspaced joists disposed between and substantially parallel to one pair ofsaid frame members, said one pair of frame members and said joistshaving undersides provided withlongitudinally extending grooves havingenlarged portions spaced from the respective undersides; at least oneL-shaped connector for at least some of said grooves, said connectorsbeing located at a level below said undersides and comprising verticalflanges having enlarged upper end portions extending into and slidablein the enlarged portions of the corresponding grooves; a ceiling paneladjacent to and located below said connectors; and a layer of adherentfoamed plastic material surrounding said connectors and adhering to saidceiling panel to connect said ceiling panel to said frame.

7. In a prefabricated roof, in combination, a skeleton frame comprisingpairs of longitudinal and transverse frame members and a plurality ofspaced ceiling joists disposed between and substantially parallel to onepair of said frame members, said one pair of frame members and saidjoists having undersides provided with longitudinally extending grooveshaving enlarged portions spaced from the respective undersides, at leastsome of said grooves having elongated cutouts of a width at least equalto the width of the respective enlarged portions; at least one connectorfor at least some of said grooves, said connectors being located at alevel below said undersides and having enlarged portions extending intoand slidable in the enlarged portions of the corresponding grooves, thelength of the enlarged portions of said connectors being less than thelength of cutouts in the corresponding grooves so that each connectormay be detached once its enlarged portion is accommodated in the cutoutof the corresponding groove; a panel adjacent to said connectors andspaced by the connectors from said skeleton frame; and a layer ofadherent foamed plastic material surrounding said connectors andadhering to said panel to connect said panel to said skeleton frame.

8. In a prefabricated roof, in combination, a skeleton frame comprisingpairs of longitudinal and transverse fram members and a plurality ofspaced joists disposed between and substantially parallel to one of saidframe members, said frame members and said joists having verticle websand lower flanges disposed in horizontal planes, the lower flanges ofsaid one pair of frame members and of said joists having undersidesprovided with longitudinally extending T-grooves and each of said framemembers having a downwardly extending skirt which is substantiallycoplanar with the respective web; and at least one connector for atleast some of said grooves, said connectors being located at a levelbelow said undersides and having T-shaped beads slidably extending intothe corresponding grooves.

9. In a prefabricated roof, in combination, a metallic skeleton framecomprising pairs of longitudinal and transverse frame members and aplurality of spaced profiled joists disposed between and substantiallyparallel to one of said frame members, said one pair of frame membersand said joists comprising lower flanges having undersides provided withlongitudinally extending grooves having enlarged portions spaced fromthe respective undersides; at least one connector for each of saidgrooves, said connectors being located at a level below said undersidesand having enlarged portions extending into and slidable in the enlargedportions of the corresponding grooves, each lower flange of each of saidjoists having at least one groove; a panel adjacent to said connectors;and a layer of adherent foamed plastic material surrounding saidconnectors and adhering to said panel to connect said panel to saidskeleton frame.

10. In a prefabricated roof, in combination, a rigid metallic skeletonframe comprising pairs of longitudinal and transverse frame members anda plurality of spaced profiled joists disposed between and substantiallyparallel with one pair of said frame members, said one pair of framemembers and each of said joists having upper and lower flanges and saidflanges respectively having upper sides and undersides provided withlongitudinally extending grooves, each of said grooves having anenlarged portion spaced from the respective side; at least one connectorprovided for at least some of said grooves, said connectors havingenlarged portions extending into and slidable in the enlarged portionsof the corresponding grooves; a panel adjacent to said connectors; and alayer of adherent foamed plastic material surrounding said connectorsand adhering to said panel to connect said panel to said skeleton frame.

11. In a prefabricated roof, in combination, a skeleton frame having anupper side and an underside and comprising pairs of longitudinal andtransverse frame members and a plurality of spaced joists disposedbetween and substantially parallel to one pair of said frame members,said joists and said one pair of frame members having flanges adjacentto one of said sides and said flanges being provided with longitudinallyextending grooves having enlarged portions spaced from said one side ofthe frame; a plurality of connectors for at least some of said grooves,each connector being adjacent to said one side of the frame and havingan enlarged portion extending into and slidable in the enlarged portionof the respective groove; 21 panel adjacent to said connectors andspaced by the connectors from said skeleton frame; and a layer ofadherent foamed plastic material surrounding said connectors andadhering to said panel to connect said panel to said skeleton frame.

12. A structure as set forth in claim 11, wherein said panel and saidconnectors are provided with cooperating means for attaching the panelto said connectors.

13. A structure as set forth in claim 12, wherein said panel is a roofskin and is located above the upper side of said frame.

14. A prefabricated roof comprising, in combination, a skeleton framehaving an upper side and an under side; a plurality of connector meansarranged spaced from each other and projecting from one side of saidskeleton 11- frame, said connector means having free end portions spacedfrom said skeleton frame; a panel adjacent to said free end portions ofsaid connector means so as to be spaced from said skeleton frame; and alayer of adherent foam plastic material adhering to said connector meansand to said panel so as to connect the panel to said skeleton framewithout direct contact between said skeleton frame and said panel.

15. A prefabricated roof according to claim 14, wherein said connectormeans project downwardly from said underside of said skeleton frame andsaid panel is a ceiling panel located adjacent to the free end portionsof said downwardly projecting connector means.

References Cited by the Examiner UNITED STATES PATENTS 1,586,053 5/1926Snyder 52-729 2,059,483 11/1936 Parsons 52-489 2,804,954 9/1957Gillespie 52656 X FOREIGN PATENTS 1,276,745 11/1961 France.

567,163 1/1945 Great Britain.

FRANK L. ABBOTT, Primary Examiner.

R. S. VERMUT, Assistant Examiner.

1. IN A PREFABRICATED ROOF, IN COMBINATION, A SKELETON FRAME COMPRISINGPAIRS OF LONGITUDINAL AND TRANSVERSE FRAME MEMBERS AND A PLURALITY OFSPACED JOISTS DISPOSED BETWEEN AND SUBSTANTIALLY PARALLEL TO ONE PAIR OFSAID FRAME MEMBERS, SAID ONE PAIR OF FRAME MEMBERS AND SAID JOISTSHAVING UNDERSIDES PROVIDED WITH LONGITUDINALLY EXTENDING GROOVES HAVINGENLARGED PORTIONS SPACED FROM THE RESPECTIVE UNDERSIDES; AT LEAST ONECONNECTOR FOR AT LEAST SOME OF SAID GROOVES, SAID CONNECTORS BEINGLOCATED AT A